1IndustrIal Plants - May 2014

In the context of large chemical plants, supply, power and control systems play a determining role and facilitate optimising the performance of operations in the entire process plant. This applies not just to “megaplants” but also to single packages which form part of a more

complex system.Costruzioni Elettrotecniche Cear has been working for more than thirty years in electrical engineering and automation to assist process and plant engineering companies and has many times encountered the most diversified international plant needs ranging from material handling and storing chemical materials to the chemical treatment of substances derived from the main process.As experts in the electrical and automation fields, it is not enough to simply provide electricity and instruments, it is both fundamental and necessary to act as a client’s partner, to learn about processes and to propose, if necessary, solutions that meet their needs and those of end-users. This applies specifically to the realization of the phosphoric acid (P2O5) and sulphuric acid (H2SO4) plant in Jordan (1500 t/day of phosphoric acid and 4500 t/day of sulphuric acid) and related

facilities at the Eshidiya site, which is still under construction, for FLSmidth Italy Mineral Processing. Cear in fact created a complete automation system for the FSA (Phosphoric Sulphuric Acid) neutralization package utility.Cear began work in 2012 and is currently in the process of

providing on-field support and supervision for installation, commissioning and start-up. This however was essentially a “turnkey” operation including:• the development of customised electrical,

instrumental and control system engineering;

• design and manufacturing of power & control shelter and electrical equipment (MCC, PLC control panels, VFD panels),

• automation software development for PLC & Scada systems;

• supply of field junction boxes, local control panels, electrical and instrumental cables and, finally, earthing material.

The engineering and design study started with a P&I process engineering document, which was discussed with our client and from which the following key requirements emerged:• service reliability;• the “high” availability of an automation system;

Neutralisation Package Unit in a Chemical Plant in JordanCear realized a turnkey electrical and automation system to guarantee service reliability and easy installation

Alessandra RannoMarketing Manager, Costruzioni Elettrotecniche Cear s.r.l.

The engineering and design study started with a P&I

process engineeringdocument, which was

discussed with our client and from which

the following key requirements

emerged

View of JIFCO plant

2IndustrIal Plants - May 2014

• reduced installation time for the power and control room;

• simplification and ease of use of the operator / control system interface (HMI / Scada).

Redundancy for service reliabilityOperational continuity was achieved by an engineering design that aimed to maintain a state of system redundancy in terms of both electrical/instrumental supply.On the electrical engineering side, to ensure power to the system even in the event of a power failure and to prevent interruptions in the production process, Cear designed an automatic switching system between the main network and a generator powered backup network.Power distribution and motor control is provided by a Power Motor Control Center (PMCC) with withdrawable units; when set up correctly, this

solution provides optimum continuity of service as well as simple inspection and maintenance procedures for the motor control centre units.The PMCC with its withdrawable units was specially designed so that the system can constantly analyse voltage and frequency values on the two incoming lines. In the event of a fault on the main incoming line, the generator starts and the breaker switches open to provide network requirements. When power is restored, the main line automatically returns to its initial configuration.In any case, the user can also have the option to switch the networks manually at its own discretion, through the use of a security key.On the other hand, redundancy of the control system was achieved by using two CPU (Central Processing Units) and redundant distributed periphery from a separate UPS (Uninterruptible Power Supply) system which guarantees power even in the event of a power failure at the plant.The aim of this technical solution was to keep the reliability of “high” automation. In the event of a failure of the main control unit, a backup unit takes over operating the system. This means that production and control can continue and real-time faults, errors and interruptions in communication can be controlled.

Easy to use automation systemThe automation system was designed using the latest generation software solutions and international brand names that can be easily found anywhere. The system acquires data, monitors and controls a variety of functions and remote processes from a centralised location in the power & control room inside the plant.The automation software collects data on process “statuses” and “measurements” from a large number of points in the plant system. This data is sent to a single data centre (PLC) which quickly puts together a large number of parameters that are displayed on the Scada system in manner that is intuitive for the operator.This means that the end user can have the following information in real-time:• the dynamic display of electrically and

electronically controlled device status;• the possibility of manually controlling all other

electric and electronic devices;

The power & control cabin

Inside the cabin

In the event of a fault on the main incoming line, the generator starts and the breaker switches open to provide network requirements

3IndustrIal Plants - May 2014

• the possibility of sending commands and plant management programs using the function keys on the operating console with guided menus from the relevant video-graphic page;

• main plant parameter display and settings;• access to automatic and manual plant control

functions with several password levels;• the acquisition, display and archiving of alarms

in compliance with ISA directives;• signals relating to plant working status and

controlled devices;• production report.

The control room designed for fast installationAll the power and control panels, switchboards (PMCC, PLC control panel and VFD panels) and the Scada station were placed in a containerised power & control room. The ISO Standard-High Cube 40 foot container was designed for extreme environmental conditions such as deserts where there is a high degree of temperature changes. The container was completely insulated and designed with backup air conditioning to provide the electrical equipment inside with insulation from outside temperatures and to ensure good operating conditions.The choice of containerised solution offers multiple benefits not only in terms of cost compared to a prefabricated control room, but also in a considerable reduction in the time required for both installation and whole system testing.The fully equipped containerised power & control room comes out of the factory fitted with electrical panels and auxiliary equipment which means that all the power equipment and power and control panels are subjected to an integrated FAT (Factory

Acceptance Test) procedures in which every single function of the automation system is simulated and tested to minimise the margin of error that may occur under normal conditions during SAT (Site Activity Test) activities.Once tested, the container is shipped to the field where it only needs to be mounted on suitable plinths and be connected to the power grid.

Choice of field materials for an aggressive environmentAs regards the engineering plant, further measures were put in place to ensure continuity of service. The choice of electrical and instrumental equipment for the field is crucial when the severe desert environment is taken into account. It was decided to use armoured cables with high performance insulation to prevent potential mechanical or other failures due to extreme

A view of the MCC

The Scada station

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temperatures or acid vapours. The cables were laid in different zinc coated steel ducts depending on voltage and function. The control stations and junction boxes installed in the field are also made of AISI 304 stainless steel which is highly resistant to corrosion.

ConclusionsA system with high reliability and low installation costs designed to minimise installation times and

margins of error before and during installation in the field. The benefit of supplying containerised solutions not only makes economic sense, it also involves direct contact with the end user with a shared goal of analysing and solving electrical and plant engineering problems to produce an integrated solution. This also minimises the misunderstandings that can so easily arise when dealing with multiple suppliers. Such “turnkey” projects involve only three parties: the end user, you and Cear, the System Integrator.

Alessandra Ranno Alessandra has studied Languages and Communication, then graduated in Marketing & Communication at the University of Milan. She’s in Cear since 2010 and she’s in charge as Marketing

Manager for coordinating marketing activities, implement international markets and support sales team.

A detail of HMI